US11908645B2 - Enabling equipment to withstand and control the effects of internal arcing faults - Google Patents

Enabling equipment to withstand and control the effects of internal arcing faults Download PDF

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US11908645B2
US11908645B2 US17/879,991 US202217879991A US11908645B2 US 11908645 B2 US11908645 B2 US 11908645B2 US 202217879991 A US202217879991 A US 202217879991A US 11908645 B2 US11908645 B2 US 11908645B2
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equipment
conductors
current
recited
conductor
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US20230197377A1 (en
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Matthew C. Nunn
Michael W. Wactor
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Powell Electrical Systems Inc
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Powell Electrical Systems Inc
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H33/00—High-tension or heavy-current switches with arc-extinguishing or arc-preventing means
    • H01H33/02—Details
    • H01H33/04—Means for extinguishing or preventing arc between current-carrying parts
    • H01H33/12—Auxiliary contacts on to which the arc is transferred from the main contacts
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H33/00—High-tension or heavy-current switches with arc-extinguishing or arc-preventing means
    • H01H33/02—Details
    • H01H33/26—Means for detecting the presence of an arc or other discharge
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02H—EMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS
    • H02H1/00—Details of emergency protective circuit arrangements
    • H02H1/0007—Details of emergency protective circuit arrangements concerning the detecting means
    • H02H1/0015—Using arc detectors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02H—EMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS
    • H02H7/00—Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions
    • H02H7/22—Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions for distribution gear, e.g. bus-bar systems; for switching devices
    • H02H7/222—Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions for distribution gear, e.g. bus-bar systems; for switching devices for switches
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02H—EMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS
    • H02H7/00—Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions
    • H02H7/26—Sectionalised protection of cable or line systems, e.g. for disconnecting a section on which a short-circuit, earth fault, or arc discharge has occured
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02H—EMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS
    • H02H9/00—Emergency protective circuit arrangements for limiting excess current or voltage without disconnection
    • H02H9/02—Emergency protective circuit arrangements for limiting excess current or voltage without disconnection responsive to excess current

Definitions

  • the present invention relates generally to electrical power equipment, and more particularly to reducing the fault energy in areas where the power circuit of the electrical power equipment (e.g., arc-resistant switchgears, motor control centers or other equipment, such as medium-voltage motor control centers rated as arc-resistant in accordance with the Institute of Electrical and Electronics Engineers (IEEE) guide for testing switchgears rated up to 52 kV for internal arcing faults, such as IEEE C37.20.7-207) is accessible through exterior doors and covers.
  • the power circuit of the electrical power equipment e.g., arc-resistant switchgears, motor control centers or other equipment, such as medium-voltage motor control centers rated as arc-resistant in accordance with the Institute of Electrical and Electronics Engineers (IEEE) guide for testing switchgears rated up to 52 kV for internal arcing faults, such as IEEE C37.20.7-207
  • IEEE Institute of Electrical and Electronics Engineers
  • An arc fault is a high power discharge of electricity between two or more conductors. Such arc faults may occur internally within electrical power equipment (also referred to herein as simply “electrical equipment”). These “internal arcing faults” may be said to be abnormal events that are not addressed by the normal operation of the electrical equipment.
  • Normal operation involves providing the ability to interrupt and clear short-circuit events that occur down-stream from the equipment on the circuit load.
  • the electrical equipment requires other devices that are located upstream from it to interrupt the short-circuit current.
  • the upstream device sees the fault as a load side short-circuit and will perform its normal functions to interrupt that short-circuit.
  • arc-resistant switchgear To protect personnel around the equipment experiencing the fault, a design referred to as “arc-resistant switchgear” was created. This design is intended to withstand and control the effects of the internal arcing fault to provide time for the upstream protection to operate and clear the fault.
  • the arc-resistant switchgear is designed to redirect arc energy up and out of the equipment, such as via ducts/vents, away from equipment operators.
  • the plasma produced by the arc energy may escape through openings created by the structural failure of the equipment, the openings of covers and doors, or through gaps between components of the assembly.
  • the arc energy may also root on the walls of the equipment and erode that material thereby creating holes for the plasma to escape.
  • arcs are totally random in both the location where they begin and in the energy they can produce.
  • the arc energy is based on the short-circuit current level and the arc voltage.
  • the arc voltage is controlled by the length of the arc, which can vary dramatically during an event. Arc-resistant equipment needs to be able to withstand and control these hazardous effects until the upstream protection can operate.
  • an equipment with arc-resistant capability comprises a bus configured to provide three-phase power from an incoming line.
  • the equipment further comprises a current loop formed from a first conductor and a second conductor, where a current is received from the bus.
  • the current loop uses electromagnetic forces of a short-circuit current caused by an internal arcing fault of the equipment to move the first and second conductors relative to each other, where the current loop creates a gap between the first and second conductors in response to the movement of the first and second conductors and where a new arc ignites at the gap.
  • a method for improving control of an internal arc fault occurring within an equipment comprises forming a current loop from a first conductor and a second conductor, where the current loop uses electromagnetic forces of a short-circuit current caused by an internal arcing fault of the equipment to move the first and second conductors relative to each other.
  • the method further comprises creating a gap between the first and second conductors by the current loop in response to the movement of the first and second conductors, where a new arc ignites at the gap.
  • FIG. 1 illustrates a current loop in accordance with an embodiment of the present disclosure
  • FIG. 2 is a flowchart of a method for improving the control of an internal arc fault occurring within an electrical equipment in accordance with an embodiment of the present disclosure
  • FIGS. 3 A- 3 B illustrate a motor control center in accordance with an embodiment of the present disclosure
  • FIG. 4 illustrates an enlarged view of a current loop for the motor control center in accordance with an embodiment of the present disclosure
  • FIG. 5 illustrates the break point of a current loop in accordance with an embodiment of the present disclosure
  • FIG. 6 illustrates a CLS-24R peak let-through curve in accordance with an embodiment of the present disclosure
  • FIGS. 7 A- 7 D illustrate arc voltage waveforms in accordance with an embodiment of the present disclosure.
  • electrical arcs are totally random in both the location where they begin and in the energy they can produce.
  • the arc energy is based on the short-circuit current level and the arc voltage.
  • the arc voltage is controlled by the length of the arc, which can vary dramatically during an event.
  • Arc-resistant equipment needs to be able to withstand and control the hazardous overpressure and high-temperature gases created by the arc energy until the upstream protection can operate.
  • the embodiments of the present disclosure provide a means for enabling arc-resistant equipment to withstand and control the effects of electrical arcs until the upstream protection can operate.
  • the arc fault effects are controlled by controlling where the electrical arc moves within the equipment (e.g., arc-resistant switchgear, motor control center).
  • the high current present during a short-circuit creates an electromagnetic force that acts on the conductors (e.g., bus bars or cables) causing them to move in a specific direction defined by the left-hand rule.
  • the conductors e.g., bus bars or cables
  • the conducting wire experiences a force perpendicular both to that field and to the direction of the current flow (i.e., they are mutually perpendicular).
  • current (I) in the direction of the middle finger and magnetic flux ( ⁇ ) corresponding to the index finger indicates force (F) in the direction of the thumb.
  • FIG. 1 illustrates a current loop 100 with a length (L) 101 and a distance (D) 102 in accordance with an embodiment of the present disclosure.
  • Current (I) 103 moves in the direction shown or clockwise from the top of the loop to the bottom, thereby causing force (F) 104 to be exerted on the top and bottom portions of the current loop in opposite directions.
  • F force
  • the force increases with increasing current (I) and length (L), but decreases with increasing distance (D).
  • the same electromagnetic forces that can move the bus during a short-circuit event can be utilized to separate conductors in the power circuit and introduce an arc that will: (1) create a series resistive element that will reduce the arc energy at the initial fault point, and (2) transfer significant levels of arc energy to a point where that energy can be more easily controlled and directed away from where personnel may be working.
  • the principles of the present disclosure do not attempt to interrupt current flow or commutate the arcing fault into a bolted fault with the design. Instead, the principles of the present disclosure take advantage of a phenomenon that naturally occurs during a short-circuit and use it to reduce the arc energy at the point of initiation and relocate the energy release point to an area closer to an exhaust vent for the equipment design.
  • the equipment enclosure may be designed to withstand, control, and direct the arc by-products.
  • the current loop design should it fail to open, does not impede this activity.
  • the loop provides a consistent focal point for the arc, regardless of where the initial fault occurs within the equipment, with little or no additional cost.
  • the equipment may be a switchgear, a motor control center (MCC), a medium-voltage MCC, a low-voltage MCC, or the like.
  • MCC motor control center
  • the design introduces a loop of bus bar that will, under conditions of an internal arcing short-circuit of a certain magnitude, use the electromagnetic forces of that short-circuit current to push the bus bars in the loop away from each other, creating a gap between the conductors where a new arc will ignite.
  • the arc being a resistive element, will reduce the fault current level at the original arc initiation point and cause the arc energy to root itself at the point where the current loop opens at a desired location of the equipment. In doing so, the energy release becomes consistent and more manageable.
  • This technique also serves to move the hazardous energy of the arcing fault away from undesirable areas and relocates that energy closer to a pressure relief venting location. Moving the arc energy away from undesirable areas, such as the access doors and covers, reduces the mechanical stresses on the equipment and helps to minimize the duration of fault gas exposure seen by the equipment, such as the door frame seams.
  • the current loop is designed to remain connected during down-stream short-circuit events thereby allowing the current-limiting fuse to clear the fault during normal operation of the equipment.
  • a “current loop” is created by forming the bus such that the conductor extends from the main bus for a distance and then returns via a second conductor to connect with the vertical riser bus in close proximity to the main bus. Since there is very little impedance in the conductor, the voltage drop across the loop is very small and there is no risk of the system voltage breaking down across the loop. As a result, the gap between the conductors can be very small, where such a distance between the conductors may be used to determine the electromagnetic forces exerted by the current flow as discussed above.
  • MCC medium-voltage motor control center
  • MCCs or MVMCCs are assemblies to control some or all electric motors in a central location.
  • a MCC may include multiple enclosed sections having a common power bus where each section contains a combination starter, which in turn includes a motor starter, fuses or circuit breaker, and a power disconnect.
  • a MCC may also include push buttons, indicator lights, variable-frequency drives, programmable logic controllers, and metering equipment. MCCs are typically found in large commercial or industrial buildings where there are many electric motors that need to be controlled from a central location, such as a mechanical room or electrical room.
  • FIG. 2 is a flowchart of a method 200 for improving the control of an internal arc fault occurring within an electrical equipment in accordance with an embodiment of the present disclosure.
  • a current loop such as current loop 100 , is formed from a first conductor and a second conductor.
  • step 202 current, such as from a bus (e.g., a bus configured to provide three-phase power from an incoming line), is received, where the current flows through current loop 100 from a starting end of the first conductor towards an opposite end of the first conductor or a connection point electrically connected to the second conductor. Furthermore, the current flows from the connection point or a starting end of the second conductor towards an opposite end of the second conductor.
  • a bus e.g., a bus configured to provide three-phase power from an incoming line
  • step 203 current loop 100 uses the electromagnetic forces of a short-circuit caused by an internal arcing fault to move the first and second conductors relative to each other.
  • a gap between the first and second conductors is created by the current loop, such as current loop 100 , in response to the movement of the first and second conductors, where a new arc ignites at the gap.
  • FIGS. 3 A- 3 B illustrate a nonlimiting example of a sectioned side view and a rear view of a motor control center 300 (e.g., Powell® MVMCC), respectively, in accordance with an embodiment of the present disclosure.
  • a motor control center 300 e.g., Powell® MVMCC
  • MCC 300 includes a main bus 302 (e.g., a bus configured to provide three-phase power from an incoming line) and a vertical riser bus 303 (e.g., a bus configured to distribute power).
  • main bus 302 e.g., a bus configured to provide three-phase power from an incoming line
  • vertical riser bus 303 e.g., a bus configured to distribute power.
  • the circled area in each view shows the location of current loop 100 ( FIG. 1 ).
  • FIG. 4 illustrates an enlarged view of current loop portion 100 ( FIG. 1 ) of motor control center 300 ( FIG. 3 ) in accordance with an embodiment of the present disclosure.
  • the details shown in FIG. 4 are nonlimiting dimensions and details applicable to examples discussed herein.
  • a first conductor or top portion 401 of the current loop that extends unsupported from a portion of a bus, such as the main bus, for a desired distance and a second conductor or bottom portion 402 of the current loop that connects with another portion of the bus, such as the vertical riser bus 303 , in close proximity to the bus create a “current loop” 100 .
  • first conductor 401 is electrically connected to the main bus 302 or the like, and the opposite end is electrically connected to the first end of second conductor 402 .
  • the opposite end of second conductor 402 is electrically connected to the vertical riser bus 303 or the like.
  • a portion of first conductor 401 and second conductor 402 form current loop 100 with a length (L) of the loop and distance (D) between the two conductors or the top and bottom portions of the current loop.
  • the width and thickness of the conductors 401 , 402 may be any suitable value, but the nonlimiting example shown generally conforms to dimensions of similar components of the bus.
  • first conductor 401 and second conductor 402 are secured together for electrical connection via any suitable fasteners, such as a nut and bolt of a desired size.
  • the current (I) 103 flows through loop 100 in the direction shown by the arrows.
  • current (I) 103 flows through loop 100 from the start of first conductor 401 via a bus connection towards connection point 403 with second conductor 402 , and from connection point 403 towards the opposite end of second conductor 402 back to another suitable bus connection.
  • the connection of first conductor 401 to main bus 302 and the connection of second conductor 402 to vertical riser bus 303 are chosen to facilitate a desired current flow direction.
  • current loop 100 may be connected to the components of a bus in any suitable manner desired that forms a current loop.
  • at least one current loop is provided for each phase.
  • three current loops may be provided for the three phases of the MVMCC equipment (see FIG. 3 B ).
  • the equipment down-stream of loop 100 may be protected by a current-limiting fuse.
  • the length (L) of loop 100 is 4.75 inches and the distance (D) is 0.24 inches.
  • the thickness of both conductors 401 , 402 is 0.25 inches and the length of a horizontal portion of second conductor 402 is 7.50 inches. It shall be apparent to one of ordinary skill in the art the dimensions are applicable to the example shown, but may be modified without undue experimentation for other embodiments with different ratings.
  • FIG. 5 illustrates the break point of current loop 100 corresponding to FIG. 4 in accordance with an embodiment of the present disclosure.
  • current loop 100 is designed to break at the point shown in FIG. 5 when forces caused by the short-circuit current exceed a predetermined level for current loop 100 .
  • loop 100 is formed by a first conductor 401 and second conductor 402 .
  • the first and second conductors 401 , 402 form current loop 100 with length (L) and distance (D) between the two conductors or the top and bottom portions of loop 100 .
  • the values for L and D may be selected as desired for the particular applications in accordance with the discussion provided herein.
  • the current (I) 103 flows through loop 100 from the start of first conductor 401 towards the connection point 403 with second conductor 402 , and from said connection point 403 towards the opposite end of second conductor 402 (broken arrows). Examples discussed herein involve copper conductors 401 , 402 , but other embodiments may contemplate other conductive materials.
  • first and second conductors 401 , 402 are electrically connected and form a connection point secured together with a suitable fastener 501 .
  • fastener 501 allows the first and second conductors 401 , 402 to be secured together with a desired clamping force at connection point 403 .
  • Washers 502 may optionally be provided between the surfaces of fastener 501 and first and second conductors 401 , 402 .
  • the desired clamping force (N) 503 is influenced by the performance desired from current loop 100 .
  • the nonlimiting example shown utilizes a suitable nut and bolt as the fastener 501 .
  • the fastener 501 or break point between first and second conductors 401 , 402 needs to hold together at the current levels at and below the predetermined limits of a fuse, such as a downstream current-limiting fuse, so that the fuse can operate to interrupt current as it is intended for the MCC equipment or the like.
  • a fuse such as a downstream current-limiting fuse
  • design factors of current loop 100 such as length, distance, clamping force (N), and conductor materials or friction coefficient ( ⁇ ), are selected to allow current loop 100 to remain closed at the current levels of the fuse rating.
  • one of the openings in one of conductors 401 , 402 is significantly larger than the diameter of fastener 501 , slotted or the like.
  • the nonlimiting example shown illustrates a slotted opening 504 in second conductor 402 , whereas, the other opening 505 in first conductor 401 is just large enough for fastener 501 to fit through.
  • Fault currents beyond the peak let-through interrupting capability of the fuse are indicative of where the current loop operation is desirable for an internal arcing fault.
  • the mating surfaces of current loop 100 provide sufficient frictional force to withstand multiple down-stream load faults where the peak let-through current is reached and not open the loop.
  • a force (F) is created by a symmetrical fault current (see Equation 2).
  • the loop opens due to movement (M) of first and second conductors 401 , 402 in opposite directions (see broken arrows).
  • the oversized or slotted opening 504 allows the first and second conductors 401 , 402 to move relative to each other when the force caused by the current loop exceeds a desired amount of separation force (F s ). This movement allows the current loop, such as current loop 100 , to create a gap between the conductors, such as conductors 401 , 402 , where a new arc will ignite.
  • the movement does not shear fastener 501 .
  • such a force is only on loop 100 until the fuse clears (e.g., maximum of 8.3 ms).
  • the length of current loop 100 the distance between conductors 401 , 402 of current loop 100 , the clamping force, and materials ( ⁇ , frictional coefficient) are factors relevant and carefully selected so that current loop 100 will separate or open at a desired fault current or greater.
  • the separation force (F s ) at which current loop 100 creates a gap between the conductors, such as conductors 401 , 402 , where a new arc will ignite can be tuned in accordance with the above noted factors for different MCCs, equipment, or the like.
  • the maximum short-circuit current desired for the equipment is 50 kA rms sym.
  • the peak current for a 50 kA rms sym fault is 130 kA at the crest of the first current cycle.
  • the equipment down-stream of the contactor assembly is protected by a current-limiting fuse.
  • the highest rated fuse used is a 7CLS-24R which goes into current limiting mode at 42 kA and has a peak let-through current of 60 kA as illustrated in FIG. 6 .
  • FIG. 6 illustrates various peak let-through curves, such as CLS-24R, in accordance with an embodiment of the present disclosure.
  • the available 50 kA rms (root mean square) current corresponds to a 60 kA peak.
  • a 42 kA peak corresponds to an available 16 kA rms current.
  • Equation 1 Using Equation 1 and the dimensions of the nonlimiting example of FIG. 4 for a symmetrical fault of 50 kA (60 kA peak let-through):
  • F 0.12 ( 50 ) 2 ⁇ ( 4.75 ) 0.24
  • F 5 , TagBox[",", “NumberComma”, Rule[SyntaxForm, "0"]] 937.5 lbs .
  • force For a symmetrical fault of 16 kA (42 kA peak let-through): F 608 lbs. force
  • a 5/16-18 grade 5 bolt is utilized as a fastener, such as fastener 501 of FIG. 5 , in the nonlimiting example to secure first and second conductors, such as conductors 401 , 402 , together.
  • fastener 501 provides a torque equal to 22 ft-lbs. and a clamping force (N) equal to 3,338 lbs.
  • the frictional force at the current loop mating surface or connection point 403 is designed to hold 5,937.5 lbs. of force applied to the bar.
  • the fuse remains in normal time-current melting mode and the maximum sustained forces applied to current loop 100 will be less than 608 lbs. for a symmetrical fault of 16 kA, which is below the force required to overcome the frictional clamping force or separation force (F s ).
  • the fuse moves into a current-limiting mode and will only allow current flow for a maximum of a 1 ⁇ 2 cycle (0.0083 s on a 60 Hz system).
  • the current loop design of the present disclosure allows the downstream fuse of the equipment, or the MVMCC in this case, to operate in a normal manner.
  • the force created by the maximum available symmetrical fault current of 50 kA (60 kA peak let-through) is 5,937.5 lbs., which is greater than the frictional clamping force (e.g., F s ⁇ 5,340 lbs.). This force is only on the loop until the fuse clears (e.g., maximum of 8.3 ms).
  • FIGS. 7 A- 7 D show traces from the arc fault testing in accordance with an embodiment of the present disclosure.
  • FIG. 7 A illustrates the arc voltage for the A-phase (one of the three phases of the MVMCC equipment).
  • FIG. 7 B illustrates the arc voltage for the B-phase (one of the three phases of the MVMCC equipment).
  • FIG. 7 C illustrates the arc voltage for the C-phase (one of the three phases of the MVMCC equipment).
  • FIG. 7 D illustrates the arc voltage for the ground current, where the loop operation of the present disclosure reduces the arc energy at the point of initiation and relocates the energy release point to an area closer to an exhaust vent for the equipment design.
  • the current loop may be formed from two conductors, and the current loop may have a length (L) of parallel conductors of the loop and distance (D) between the two conductors.
  • Current (I) flows through the current loop from the starting end of a first conductor towards the opposite end or the connection point electrically connected to a second conductor. The current flows from the connection point or starting end of the second conductor towards the opposite end of the second conductor.
  • the starting end of the first conductor receives current from the equipment or MCC, such as a bus (e.g., bus 302 ) of the equipment or MCC, and the opposite end of the second conductor returns current to another portion of the equipment or MCC, such as another bus (e.g., bus 303 ) of the equipment or MCC.
  • a fastener such as a nut and bolt, allows the first and second conductors to be secured together with a desired clamping force at the connection point. Due to the current flow through the current loop, a force may be exerted on the conductors in opposing directions due to the left-hand rule for magnetic force.
  • An oversized opening either in the first or second conductor, allows the first and second conductor to move relative to each other when the force caused by the current loop exceeds a desired amount of separation force (F s ). The movement allows the current loop to create a gap between the two conductors where a new arc will ignite.
  • the current loop is designed to create a gap when a fault or symmetrical fault exceeds a predetermined amount, such as 50 kA or greater.
  • the length (L) of the current loop is 4.75 inches.
  • the distance (D) between the conductors of the loop is 0.24 inches.
  • the conductors are copper.
  • the separation force is 5,937.5 lbs.
  • Embodiments described herein are included to demonstrate particular aspects of the present disclosure. It should be appreciated by those of skill in the art that the embodiments described herein merely represent exemplary embodiments of the disclosure. Those of ordinary skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments described, including various combinations of the different elements, components, steps, features, or the like of the embodiments described, and still obtain a like or similar result without departing from the spirit and scope of the present disclosure. From the foregoing description, one of ordinary skill in the art can easily ascertain the essential characteristics of this disclosure, and without departing from the spirit and scope thereof, can make various changes and modifications to adapt the disclosure to various usages and conditions. The embodiments described hereinabove are meant to be illustrative and should not be taken as limiting of the scope of the disclosure.

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